2001 DODGE RAM Service Repair Manual

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Page 1649 of 2889

DODGE RAM 2001 Service Repair Manual (11) Remove first gear needle bearing (Fig. 37).
(12) Remove output shaft bearing snap ring (Fig.
38).
(13) On 2-wheel drive models, remove output shaft
bearing.
(14) Remove fifth gear (Fig. 39).
(15)

Page 1650 of 2889

DODGE RAM 2001 Service Repair Manual REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 44).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean

REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 44).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and trans-
mission housings with a standard parts cleaning sol-
vent. Do not use acid or corrosive base solvents. Dry
all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such
as Mopartdegreasing solvent, Gunk, or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels.
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball, or internal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 45). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks, or scores. The plunger spring should be straight
and not collapsed, or distorted. Minor scratches, or
nicks on the plunger can be smoothed with 320/400
grit emery soaked in oil. Replace the plunger and
spring if in doubt about condition. Check condition of
detent plunger bushings. Replace if damaged.
Inspect the shift shaft, shift shaft bushing and
bearing, the shaft lever, and the lever bushing that
fits over the lever. Replace the shaft if bent, cracked,
or severely scored. Minor burrs, nicks, or scratches
can be smoothed off with 320/400 grit emery cloth
followed by polishing with crocus cloth. Replace the
shift shaft bushing or bearing if damaged.
Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the roll
pin that secures the lever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores, or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file,
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
Fig. 42 Fifth-Reverse Synchro
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 43 Reverse Gear And Needle Bearing
1 - REVERSE GEAR AND NEEDLE BEARING
BR/BEMANUAL - NV3500 21 - 15
MANUAL - NV3500 (Continued)

Page 1651 of 2889

DODGE RAM 2001 Service Repair Manual NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
fron

Page 1652 of 2889

DODGE RAM 2001 Service Repair Manual Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth a

Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the
retainer seal if necessary.
Inspect the output shaft bearing retainer. Be sure
the U-shaped retainer is flat and free of distortion.
Replace the retainer if the threads are damaged, or if
the retainer is bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft bearings can be installed back-
wards if care is not exercised. The bearing roller cage
is a different diameter on each side. Be sure the
bearing is installed so the large diameter side of the
cage is facing the countershaft gear (Fig. 46). The
small diameter side goes in the bearing race.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted, or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace the thrust washer, wave washer, or thrust
plate if cracked, chipped, or worn. Replace the idler
gear if the teeth are chipped, cracked or worn thin.
Replace the shaft if worn, scored, or the bolt threads
are damaged beyond repair. Replace the support seg-
ment if cracked, or chipped and replace the idler
attaching bolts if the threads are damaged.
Shift Socket
Inspect the shift socket for wear or damage.
replace the socket if the roll pin, or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn, or cracked. Do not reuse the original
shift socket roll pin. Install a new pin during reas-
sembly. The socket roll pin is approximately is
approximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all of the gears for worn, cracked, chipped,
or broken teeth. Also check condition of the bearing
bore in each gear. The bores should be smooth and
free of surface damage. Discoloration of the gear
bores is a normal occurrence and is not a reason for
replacement. Replace gears only when tooth damage
has occurred, or if the bores are brinnelled or
severely scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-
aged or bearing surfaces are deeply scored, worn, or
brinnelled.
ASSEMBLY
Gaskets are not used in this transmission. Sealers
are used at all case joints. Recommended sealers are
Mopar Gasket Maker for all case joints and Mopar
silicone sealer, or equivalent, for the input shaft
bearing retainer. Apply these products as indicated in
the assembly procedures.
NOTE: The transmission shift components must be
in Neutral position during assembly. This prevents
damaging to the synchro and shift components
when the housings are installed.
Fig. 46 Countershaft Bearings
1 - COUNTERSHAFT
2 - BEARING CAGE
BR/BEMANUAL - NV3500 21 - 17
MANUAL - NV3500 (Continued)

Page 1653 of 2889

DODGE RAM 2001 Service Repair Manual The 3-4, 1-2 and fifth-reverse synchro hub snap
rings can be fitted selectively. New snap rings are
available in 0.05 mm (0.0019 in.) thickness incre-
ments. Use thickest snap ring that will fit in ea

The 3-4, 1-2 and fifth-reverse synchro hub snap
rings can be fitted selectively. New snap rings are
available in 0.05 mm (0.0019 in.) thickness incre-
ments. Use thickest snap ring that will fit in each
snap ring groove.
SYNCHRONIZER
To assemble each synchro install the springs,
struts and detent balls one at a time as follows:
(1) Slide sleeve part way onto the hub. Leave
enough room to install the spring in the hub and the
strut in the hub groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub just far enough to
hold the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
carefully work the sleeve over the ball to hold it in
place. A small flat blade screwdriver can be used to
press the ball into place while moving the sleeve over
it.
(5) Repeat procedure for the remaining springs,
struts and balls. Tape or a rubber band can be used
to temporarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 47).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with rec-
ommended lubricant during assembly. Petroleum
jelly can be used to hold parts in place. Immerse
each synchro ring in lubricant before installation.
(1) Lubricate and install reverse gear needle bear-
ing on shaft (Fig. 48). Slide bearing up against shoul-
der on output shaft.
(2) Install reverse gear over needle bearing (Fig.
49).
(3) Install brass synchro ring on reverse gear (Fig.
50).
(4) Assemble fifth-reverse synchro hub, sleeve,
struts, springs and detent balls, if not previously
done.
CAUTION: One side of the hub has shoulders
around the hub bore, this side of the hub faces the
front of the shaft. One side of the sleeve is tapered
the tapered side faces the front of the shaft.
Fig. 47 Synchronizer Components
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
Fig. 48 Reverse Gear Bearing
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 49 Reverse Gear
1 - REVERSE GEAR
21 - 18 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

Page 1654 of 2889

DODGE RAM 2001 Service Repair Manual (5) Start fifth-reverse synchro assembly on output
shaft splines by hand. Then seat synchro onto shaft
with shop press and Remover 6310-1 (Fig. 51).(6) Install the thickestnewfifth-reverse hub snap
ri

Page 1655 of 2889

DODGE RAM 2001 Service Repair Manual (8) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 54).
Verify bearing is properly seated.
(9) Install fifth gear on shaft and onto bearing
(Fig. 55).
(

Page 1656 of 2889

DODGE RAM 2001 Service Repair Manual (13) Install first gear synchro ring (Fig. 58).
(14) Assemble 1-2 synchro hub sleeve, springs,
struts and detent balls.
CAUTION: One side of the synchro sleeve is
marked First Gear Side. This side of

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